Simple mirror sail seal for fixed sail construction

ABSTRACT

A one-piece composite mirror sail is disclosed for an associated vehicle that eliminates use of metal brackets. The sail includes a glass run that extends from beneath a belt line of a vehicle door window opening and extends above the associated belt line. A first portion of the glass run is an extruded EPDM first portion that extends from beneath the associated belt line. A second portion of the glass run is located above the belt line and is molded thermoplastic only. The first and second portions of the glass run are integrally joined, preferably along a fusion bonding interface. A coating is preferably provided on a base and seal lips of the extruded portion. An angled leg extends from the glass run second portion. The angled leg includes a retaining portion. The angled leg and retaining portion are molded thermoplastic only.

This application claims priority from U.S. provisional application Ser. No. 60/627,532, fled Nov. 12, 2004, the disclosure of which is incorporated herein by reference.

BACKGROUND OF THE INVENTION

The present invention relates to a corner piece for an automobile, and more particularly to a mirror sail seal, that uses different materials at different portions of the mirror sail seal, i.e., specific part geometry, to improve on performance, cost, and ease of assembly.

U.S. Pat. No. 5,746,471 is one representative example of a corner piece such as a mirror sail seal used in an automotive vehicle. The '471 patent generally teaches an EPDM channel received in a metal bracket. It is common to extrude a channel-shaped EPDM over a U-shaped metal bracket and attach the EPDM in a suitable manner to the bracket.

An alternative structural arrangement for a mirror sail seal manufactures the component as a molded component, such as EPDM. Unfortunately, the shape of the sail seal is constrained by molding, thus, a molded EPDM mirror sail seal is not as desirable because of extended cycle times, and the need for the component to vulcanize.

There are competing functions of the sail seal. It will be appreciated that a portion of the component must be sufficiently rigid so as to eliminate the need for metal reinforcement or use of metal to secure the component to the vehicle. On the other hand, one portion of the mirror sail seal must be sufficiently conforming or soft as to form an effective, reliable seal with a moveable door glass. Still other portions of the sail seal must be more durable and resistant to glass abrasion, i.e., requiring a low-friction or slippery surface that is abrasion-resistant.

Heretofore, it is believed that no corner piece or mirror sail has been part geometry-specific, i.e., providing different materials at different locations or portions of the mirror sail seal while maintaining a one-piece arrangement for assembly purposes that serve these various functions. For example, large molds are required for an entirely molded mirror sail. Even then, multiple post-molding operations are still required such as adding flock along the glass run portions thereof. These post-molding steps increase the overall cost. In addition, such conventional materials such as flock and flock adhesive are deemed generally unfriendly to the environment.

Thus, a need exists for ease in manufacturing of a simple mirror sail seal that is environmentally friendly and uses materials that are recyclable while providing a final component that improves sealing performance at the same or slightly better cost.

SUMMARY OF THE INVENTION

A composite mirror sail for an associated vehicle includes a glass run extending from beneath an associated belt line of a vehicle door window opening and extending above the associated belt line. The glass run has an extruded first portion that extends from beneath the associated belt line to a location above the associated belt line, and a second portion that is molded thermoplastic only. An angled leg extends from the glass run second portion and is formed from molded thermoplastic only.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1 and 2 illustrate a conventional molded EPDM.

FIG. 3 is an elevational view of the present invention.

FIGS. 4 and 5 are cross-sectional views taken generally along the lines 4-4 and 5-5, respectively, of FIG. 3.

DETAILED DESCRIPTION OF THE INVENTION

Turning briefly to FIGS. 1 and 2, a conventional mirror sail seal assembly A is shown. The assembly is a one-piece molded EPDM seal component 10 that includes a first or glass run portion 12 that extends at an angle from an area below the belt line BL to an upper corner 14. An external edge of the glass run portion is generally channel-shaped and guides an edge of a window (not shown) as the window is selectively raised and lowered relative to the vehicle door (not shown). As will be described in greater detail below, the glass run portion is typically a generally U-shaped channel that receives an edge of the window and includes first and second lips that sealingly engage opposite surfaces of the window along the front edge. It is preferred that the glass run portion be a durable structure that provides an effective seal without imposing undue frictional forces on the window so that the window drive means (manual or electric) can remain sufficiently small or low power. A second angled portion 16 of the mirror sail seal extends forwardly from the corner 14 along the contour of the vehicle door frame, or if used in a frameless door arrangement such as a convertible vehicle, along the general profile of the front A-pillar. The second angle portion terminates in an enlarged, generally rectangular region 18 that includes an integrated push pin 20 or similar attachment feature that advantageously secures the sail seal to the vehicle.

In order to provide a low-friction surface, those regions of the glass run portion 12 adapted to engage the inner and outer surfaces of the window, and likewise the edge of the glass, such as shown in the cross-section of FIG. 2, are typically coated with a low-friction material such as flock 22. An adhesive is provided on the EPDM and the flock applied to provide the desired low-friction surface. Unfortunately, both the flock and flock adhesive are not as desirable for use due to the perceived adverse impact on the environment. Moreover, these post molding operations added to the overall cost of the component. Again, this type of molded EPDM sail seal is known in the art so that further description herein is unnecessary to a full and complete understanding of the present invention.

A preferred embodiment of the present invention as illustrated in FIGS. 3-5 replaces use of a metal bracket and EPDM extruded arrangements, or even the molded EPDM arrangement as shown in FIGS. 1 and 2. Here, glass run portion 24 is a dual material base structure comprised of a molded TPE that extends over an upper portion 26 of the sail seal (including the upper portion of the glass run) as well as a lower EPDM extruded portion 28. The TPE mold and the extruded EPDM portion are integrally joined preferably through a fusion bonding as shown at 30 along their longitudinal interface (shown here as extending at an angle to the longitudinal extent of the glass run portion of the seal). More particularly, the glass run portion 28 is formed from an extruded material such as EPDM. As shown in the cross-section of FIG. 4, the extrusion has a generally channel-shape defined by a base 32, and first and second spaced sidewalls 34, 36. The base and sidewalls define a generally U-shaped configuration forming an open interior cavity 38. Outer terminal ends of the sidewalls include a first set of seal lips 40, 42 that extend inwardly into the cavity and toward one another. Likewise, outer lips 44, 46 extend from outer terminal ends of the sidewalls for engagement with the outer, opposite surfaces of the window.

This cross-section of FIG. 4 when compared with that shown in the prior art of FIG. 2 illustrates various advantages of the present invention. As will be appreciated, the extruded channel has substantially the same conformation as that of the molded EPDM of FIG. 2 except that inwardly extending lips are now provided along substantially the entire length of the glass run portion, i.e., from approximately 100 mm below an upper corner 48 because of the extruded portion. This advantageously provides seal lips along the window that also extend below the belt line whereas prior arrangements did not extend below the belt line.

Still another advantage is that the lips provide a constraining force or stabilizing force to the window, particularly below the belt line that removes undesired movement of the window that could otherwise result in noise or rattling.

Moreover, whereas the EPDM of FIGS. 1 and 2 required a flock or other low-friction coating to be deposited in a post molding operation, the present invention shown in FIG. 5 incorporates an abrasion-resistant plastic that is durable, and has a low-friction material quality that allows the plastic to serve the durability functions required of the static, less-dynamic areas of the sail seal. A preferred abrasion resistant material is described in U.S. Pat. No. 6,660,360, entitled Laminate of a Substrate and an Extruded High-Density Polyurethane, inventor Mertzel, et al., the disclosure of which is incorporated herein by reference. Preferably, this abrasion-resistant plastic is provided in at least three distinct regions, namely, along an interior base wall 50, and along the outwardly facing surfaces 52, 54 of seal lips 40, 42. These surfaces 50, 52, 54 are adapted for engagement with opposite faces of the window, along with an edge of the window during selective raising and lowering of the window relative to the vehicle door. As indicated above, the abrasion-resistant plastic is preferably provided along these selected regions of the extrusion.

However, another embodiment merely coats the entire interior surface of the extruded glass run portion with the abrasion resistant plastic. This includes the second pair of lips 44, 46 that also engage the inner and outer surfaces of the window. Thus, the main channel of the extrusion is preferably an EPDM and the plastic is co-extruded therewith in a manner generally known in the art over the entire interior of the glass run channel such as the base, interior of the sidewalls, over the entire first set of lips, and at least along the inner surface of the second set of lips 44, 46.

This glass run channel portion extends from below the belt line BL to a region as high as possible within geometry and structural limitations—located well above the belt line, i.e., up to the interface 30. The extruded component with the abrasion resistant plastic is integrally joined with a thermoplastic elastomer (TPE) such as through a fusion bonding interface. Preferably, the remainder of the seal sail such as the second angled portion 60 and the generally rectangular attachment region 62 (including the integrated push pin(s) 64) is formed of the TPE, and is preferably molded. This has the advantage that the TPE plastic is durable, and is easier to work with than a conventionally molded EPDM. TPE is more rigid, and also has a faster cycling time. It also advantageously does not have to be vulcanized. Accordingly, some cost savings may be associated therewith. Generally, this TPE portion has the same conformation as a conventional sail seal. Thus, the cross-sectional view of FIG. 5 illustrates that the TPE does not require any external coatings as would be necessary with an EPDM. It is a generally soft plastic that conforms easily for sealing characteristics that are desired with a vehicle body. Thus, only upper portion of the glass run is a molded TPE while the remainder of the second angle leg 60 of the mirror sail is all TPE, as is the retainer portion 62. Again, structural details of the second leg and retainer portion are generally the same so that further discussion herein is deemed unnecessary to a full and complete understanding of the present invention.

The present invention uniquely uses an extruded cross-section that incorporates an abrasion-resistant, slippery surface material along selected regions to provide desirable glass run properties below the belt. In that portion of the sail seal above the belt line, the molded TPE is sufficient to serve as the remainder of the glass run length while providing improved sealing performance at a lower cost. Moreover, the exterior show surface of the molded TPE is improved since it provides a textured surface having improved aesthetics over a conventional molded EPDM. The combination of a molded/extruded mirror sail in which the extrusion trim is secured to a TPE mold is deemed to be an improvement over prior arrangements. Bonding interface of the extruded component with the TPE mold also provides a generally seamless transition that does not adversely impact on manufacture. Simultaneously, use of the TPE for the mold material has the advantage that the textured surface provides improved aesthetics in those external regions formed of the TPE for this vehicle component. The ability to maintain an integrated fastener feature is still achieved, and it also adequately bonds to the extruded EPDM component. Lastly, the abrasion-resistant plastic is easily formed on the extruded component, preferably through a co-extrusion process. By providing an extended length of glass run with flexible sealing lips that extend inwardly toward the channel cavity, improved sealing is achieved and greater stability of the window during door operation.

The invention has been described relative to the preferred embodiments. Obviously modifications and alterations will occur to others upon reading and understanding the preceding detailed description. It is intended that the invention should be construed as including all such modifications and alterations in so far as they fall within the scope of the following claims. 

1. A composite mirror sail for an associated vehicle, the sail comprising: a glass run extending from beneath an associated belt line of a vehicle door window opening and extending above the associated belt line, the glass run having an extruded first portion that extends from beneath the associated belt line to a location above the associated belt line, and a second portion that is molded thermoplastic only; and an angled leg extending from the glass run second portion that is molded thermoplastic only.
 2. The invention of claim 1 wherein the first and second portions of the glass run are integrally joined to one another.
 3. The invention of claim 2 wherein the first and second portions are fusion bonded together.
 4. The invention of claim 1 further comprising an attachment portion extending from the angled leg at an end of the leg opposite from the glass run, the attachment portion also formed of a molded thermoplastic.
 5. The invention of claim 1 wherein the first portion of the glass run includes selected portions of abrasion resistant plastic.
 6. The invention of claim 5 wherein the glass run has a base and first and second sidewalls extending outwardly therefrom to form a channel-shape in cross section including a cavity dimensioned to receive an edge of the associated door window, the base of the channel and portions of the sidewalls including an abrasion resistant plastic.
 7. The invention of claim 6 wherein the sidewall portions include a first set of seal lips that extend inwardly into the cavity for engagement with the associated window.
 8. The invention of claim 6 wherein the sidewalls include first and second sets of seal lips dimensioned to engage the associated window.
 9. The invention of claim 1 wherein the glass run has a base and first and second sidewalls extending outwardly therefrom to form a channel-shape in cross section including a cavity dimensioned to receive an edge of the associated door window, an entire internal surface of the glass run being coated in an abrasion resistant plastic.
 10. A one-piece composite mirror sail for an associated vehicle that eliminates use of metal brackets, the sail comprising: a glass run extending from beneath an associated belt line of a vehicle door window opening and extending above the associated belt line, the glass run having an extruded EPDM first portion that extends from beneath the associated belt line to a location above the associated belt line, and a second portion above the associated belt line that is molded thermoplastic only, the first and second portions integrally joined along a fusion bonding interface; and an angled leg extending from the glass run second portion that is molded thermoplastic only.
 11. The invention of claim 10 wherein the first and second portions of the glass run are integrally joined.
 12. The invention of claim 10 wherein the first and second portions of the glass run are fusion bonded.
 13. The invention of claim 10 wherein the first portion of the glass run includes a base and sidewalls extending therefrom, selected portions of which are coated with an abrasion resistant plastic.
 14. The invention of claim 10 wherein the first portion of the glass run includes a base and sidewalls extending therefrom to define a cavity that receives an edge of an associated door glass, portions of the base and sidewalls facing the cavity including an abrasion resistant plastic coextruded thereon.
 15. The invention of claim 14 wherein the sidewalls include a first set of seal lips extending inwardly into the cavity.
 16. The invention of claim 15 further comprising a second set of seal lips extending inwardly into the cavity. 